Controlling via critical dimension with a titanium nitride hard mask

ABSTRACT

An Nblock layer is deposited onto a semiconductor substrate that includes metal deposits. A titanium nitride (TiN) layer is deposited directly onto the Nblock layer; an oxide layer is deposited directly onto the TiN layer; and a via hole is formed through the oxide and TiN layer to contact bottom interconnect. The via hole is aligned to one of the metal deposits in the substrate.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a division of U.S. patent application Ser. No.16/170,009 filed 10-24-2018, the complete disclosure of which isexpressly incorporated herein by reference in its entirety for allpurposes.

BACKGROUND

The present invention relates to the electrical, electronic, andcomputer arts, and more specifically, to fabrication of semiconductorwafers.

Presently, semiconductor wafers are fabricated by deposition and etchingof materials on a substrate, usually silicon. Materials are firstdeposited and etched to form the front end of line (FEOL) circuitry suchas individual transistors, then additional layers of material aredeposited and etched to provide intermediate circuitry and finally theback end of line (BEOL) interconnects including vias. BEOL interconnectsare created using mostly a dual damascene scheme for coppermetallization with a TiN hard mask to define the trench and self-alignedvia. In some cases, single damascene is used. In both types of damasceneprocess, a nitride cap layer or “Nblock” layer is deposited onto coppercircuitry formed in an underlayer, then an oxide layer (often, anultra-low K layer) is deposited over the Nblock and a hard mask goes onover the oxide layer.

SUMMARY

Principles of the invention provide techniques for controlling viacritical dimension with a titanium nitride hard mask.

In one aspect, an exemplary method includes depositing an Nblock layeronto a semiconductor substrate that includes metal deposits; depositinga titanium nitride (TiN) layer directly onto the Nblock layer;depositing an oxide layer directly onto the TiN layer; and forming apartial-depth via hole through the oxide layer to contact the TiN layer,wherein the partial-depth via hole is aligned to one of the metaldeposits in the substrate.

In another aspect, a semiconductor wafer includes an underlayer; metaldeposits in the underlayer; a sacrificial hardmask layer that covers theunderlayer and the metal deposits; a titanium nitride layer thatdirectly covers the sacrificial hardmask layer; an oxide layer thatdirectly covers the titanium nitride layer; and a partial-depth via holethat is etched through the oxide layer to contact the titanium nitridelayer that directly underlays the oxide layer, wherein the partial-depthvia hole is aligned to one of the metal deposits in the underlayer.

In view of the foregoing, techniques of the present invention canprovide substantial beneficial technical effects. For example, one ormore embodiments provide one or more of:

Well-defined via diameter (critical dimension or CD) with minimalblowout.

Vertical via with no chamfer (in one or more embodiments, for example, achamferless via with improved minimum spacing between via and adjacentlower metal line).

These and other features and advantages of the present invention willbecome apparent from the following detailed description of illustrativeembodiments thereof, which is to be read in connection with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts in side view steps of a process for single damascene viaformation with via CD blowout due to over-etching of an oxide layerdefining the via;

FIG. 2 depicts in flowchart form the steps of FIG. 1;

FIG. 3 depicts in flowchart form steps of a process for single damascenevia formation using a titanium nitride (TiN) hard mask between an Nblocklayer and an oxide layer;

FIGS. 4A-4E depict in side view the steps of FIG. 3; and

FIG. 5 depicts schematically an exemplary computer system forcontrolling semiconductor fabrication process equipment according to anexemplary embodiment.

DETAILED DESCRIPTION

As shown in FIGS. 1 and 2, a single damascene process 100 for forming avia 223 in a semiconductor wafer 200 includes a step 104 of depositingan organic planarization layer (OPL) 212 and a silicon-containingantireflection coating (SiARC) 214 onto an oxide layer 204, whichoverlays an Nblock layer 206, a copper layer 208, and an underlayer(e.g., silicon substrate) 210. At 106, the process 100 further includesperforming via lithography on a photoresist (not shown), etching theSiARC 214 and the OPL 212, then at 108 forming holes 218 for vias 223 byetching the oxide layer 204 through openings 222 of the SiARC 214 andthe OPL 212. Typically the oxide layer 204 is etched using carbonfluoride (CF₄) dry etch, however, other dry chemistries like C₄F₈,CH₂F₂, C₄F₆ or any combination of them can be used to etch the Oxidelayers. During the relatively long etch time required to get to thebottom of the oxide layer 204, CF₄ collects at and backscatters from thebottoms of the holes 218, thereby etching sideways as well asvertically. The phenomenon of sideways etching, which enlarges thecritical dimension (diameter, CD) of each via hole 218, as shown at 224in FIG. 1, is known as “blowout”.

During the etching of layer 204, Siarc 214 is removed. After etching theoxide layer 204, at 112 the OPL 212 is stripped, for example usingN₂/H₂, He/HBr/O₂, O₂, SO₂, or CO/CO₂ chemistry. Typically, the OPLstripping chemistry also is aggressive against the oxide layer 204, andexacerbates the blowout problem. Then at 114 copper or other metal isdeposited into the via holes 218 to form the vias 223. At 116, chemicalmechanical polishing is used to remove upper portions of the oxide layer204 and of the vias 223. The remnants of the vias 223 display a bowed orsemi-elliptical cross section that is a feature of the blowoutphenomenon.

Referring now to FIGS. 3 and 4A-4E, an aspect of the invention is thatvia hole blowout can be mitigated by depositing a layer of titaniumnitride (TiN) below an oxide layer and forming completed via holes inthe TiN layer, using a Cl₂ dry etch or other dry chemistry that isselective to the oxide layer, after first forming the via holes throughthe oxide layer, using a CF₄ dry etch or other dry chemistry that isantagonistic to the oxide layer.

Accordingly, a process 300 for controlling via critical dimension with atitanium nitride hard mask is performed on a semiconductor wafer 400.The process 300 includes, at 301, depositing an Nblock layer 404 onto anunderlayer 408 that contains metal (e.g., copper) deposits 406, then at302, depositing a TiN layer 402 onto the Nblock layer 404. At 304, theprocess 300 further includes depositing an oxide layer 410 (e.g.,tetraethylorthosilicate or “TEOS”) onto the TiN layer 402. At 306, anOPL 412 and a SiARC 414 are deposited onto the oxide layer 410.

Then, referring specifically to FIG. 4A, at 308 a photoresist 415 isdeposited and partially developed. In a subsequent step (not shown), thedeveloped portions 416 a, 416 b of the photoresist 415 are removed bylithography to uncover portions of the SiARC 414. The patterning flowcould be done by a variety of sequences such as direct litho patterning,litho-etch-litho-etch (LELE), self-aligned double patterning (SADP), orother optical or EUV lithographic methods. At 309, the uncoveredportions of the SiARC 414 and OPL 412 below are removed to form openings417 a, 417 b that will respectively result in a single via and a viabar. During removal of the OPL 412, the remaining photoresist 415 alsois removed. At 310, partial-depth via holes 418 a, 418 b are formed byetching the oxide layer 410 through the openings 417 a, 417 b of theSiARC 414 and the OPL 412, using CF₄ or other dry process that isantagonistic to the oxide layer 410. The process used for etching theoxide layer is selective to the TiN 402, as well. In the same process,the SiARC is stripped; i.e., in one or more embodiments, the SiARC 414and the TEOS 410 are removed together using a dry process.

Referring now to FIG. 4B, at 312, complete the via holes 420 a, 420 b byetching the TiN layer 402 through the partial-depth via holes 418 a, 418b, using Cl₂ or other dry process that is selective to the oxide 410.Then etch the Nblock Cap layer using a CF₄ or CH₃F chemistry that isselective to the TiN 402 and TEOS 410 and underlayers 406 and 408. ThenOPL is stripped. Indeed, in one or more embodiments, because of thetransition of TEOS→TIN→Nblock, the Etch chemistry is different and hasenough selectivity to “stop” precisely on the etch layer withoutdamaging the layer below.

Accordingly, the critical dimension (CD) of the via holes 420 is nowdefined by the TiN opening. The problem of blowout is mitigated; thus,the CD of the via holes 420 is substantially constant, i.e. remainswithin 2 nm of an average value throughout the oxide layer 410 and theTiN layer 402.

Optionally, at 314 (shown only in FIG. 3), a liner 422 is deposited toimprove adhesion between the underlayer 408 and a subsequent metal layer424. The liner can be omitted if a metal other than copper is used.Still referring to FIG. 4B, at 316, single via 423 a and via bar(multi-via) 423 b are formed by depositing the metal layer 424 into thevia holes 420 a, 420 b and over the oxide layer 410. The metal layer 424can be copper or other metal such as cobalt, Tungsten, Aluminum,Tantalum or ruthenium. At 318, remove part of the metal layer 424 bychemical mechanical polishing and at 320 remove all of the oxide layer410 by CF₄ etch or similar dry process.

Referring now to FIG. 4C, at 322, remove the TiN layer 402 by a wetprocess, e.g., a TiN-selective wet chemistry that includes an oxidizingagent, metal protection agent, and a pH stabilizer in water or solventmixtures. Suitable wet chemistries comprise a quaternary ammoniumhydroxide, hydrogen peroxide, or benzotriazole passivation agents. Forexample, TiN wet removal chemistry formulation includes an oxidizingagent (preferably hydrogen peroxide) and a pH controlling agent in anaqueous solution, in addition to a sequestering agent and a metalprotection agent. The wet removal process is done typically attemperature ranges of 40-65 degrees Celsius. The pH of the formulationmay be adjusted to a range of 7 to about 14 using a base (typically aquaternary ammonium salt such as tetramethyl ammonium hydroxide ortetraethyl ammonium hydroxide). The sequestering agents can be aminesand amino acids. The preferred sequestering agents are1,2-cyclohexanediamine-N,N,N′,N′-tetraacetic acid (CDTA),ethyenediaminetetraacetic acid (EDTA) and diethylenetriaaminopentaaceticacid (DTPA). The metal protectants are in general, hetero-organicinhibitors such as azoles or thiols, preferably benzotriazoles (BTA).

Then at 324, deposit a subsequent oxide layer 426 over the Nblock layer404 and adjacent to the metal vias 423, and continue depositing theoxide layer 426 to cover the vias 423. At 326, perform chemicalmechanical polishing on the subsequent oxide layer 426. Leave athickness of oxide layer 426 sufficient for trench depth, approximately30 to 80 nm.

Referring to FIG. 4D, at 328, deposit a trench level (“Mx”) stack ofunderlayer 428, TiN 430, and tetraethylorthosilicate (TEOS) 432. At 330,deposit Mx OPL 434 and SiARC 436 onto the TEOS 432, then at 332 unmaskportions of the TEOS using the OPL 434 and the SiARC 436 mask. Whileetching TEOS 432, top Siarc 436 is removed

As shown in FIG. 4E, at 334, etch unmasked portions of the OPL 434, theTEOS 432, and the TiN 430 using a Cl2 base chemistry to open the TIN430; then, at 335 (shown only in FIG. 3), strip the OPL 434. At 336,form trenches 438 that reveal the vias 423 by etching the underlayer 428and layer 426 with a CF₄ base chemistry selective to TiN 410 andmetallized Via 423. Top Oxide layer 432 is removed during that process.Note that some of the trenches 438 are in the plane of the drawing viewwhereas some others, which appear narrower, actually extend orthogonalto the plane of the drawing view. Not all of the trenches 438 connect topreviously formed vias 423. At 338, underlayer 428, and TiN 430, areremoved by wet process. Then at 340, form via bars 440, which connectthe vias 423, by metallizing the trenches 438. In subsequent step 341(shown only in FIG. 3), the structure can be prepared for deposition ofadditional layers by reducing and planarizing the metallizing layerusing, e.g., chemical mechanical polishing.

Given the discussion thus far, it will be appreciated that, in generalterms, a BEOL interconnect is improved by using lithography to define avia in a very short stack, which improves the overlay and the uniformityof the via critical dimension CD. The short stack via etching isachieved by using titanium nitride (TiN) as a hard mask until finalmetallization, then after a copper/oxide chemical mechanical polishing(CMP), removing the TiN by wet or dry process.

Thus, an exemplary method 300, according to an aspect of the invention,includes step 301 of depositing an Nblock layer onto a semiconductorsubstrate that includes metal deposits; step 302 of depositing atitanium nitride (TiN) layer directly onto the Nblock layer; step 304 ofdepositing an oxide layer directly onto the TiN layer; and step 310 offorming a partial-depth via hole through the oxide layer to contact theTiN layer, wherein the partial-depth via hole is aligned to one of themetal deposits in the substrate. In one or more embodiments, the method300 also includes step 312 of forming a completed via hole by etchingthe TiN layer through the partial-depth via hole.

In one or more embodiments, the method 300 also includes, afterdepositing the oxide layer, a step 306 of depositing an organicplanarization layer (OPL) directly onto the oxide layer and depositing asilicon anti-reflective coating (SiARC) directly onto the OPL; a step309 of removing at least a portion of the OPL and the SiARC by etchafter lithography; and then the step 310 of forming the depth via holeby etching the oxide layer through the removed portion of the OPL andthe SiARC.

In one or more embodiments, the method 300 also includes, after formingthe depth via hole, at step 312 stripping the OPL.

In one or more embodiments, step 310 of etching the oxide layer uses aCFx chemistry for dry process.

In one or more embodiments, step 312 of etching the TiN layer uses achemistry selective to the oxide layer. For example, etching the TiNlayer uses a Cl2 dry process.

In one or more embodiments, the method 300 further includes a step 316of depositing a metal layer into the via holes and onto remnants of theoxide layer.

In one or more embodiments, the method 300 further includes a step 318of removing an upper portion of the metal layer by chemical mechanicalpolishing.

In one or more embodiments, the method 300 further includes a step 320of removing the oxide layer by a dry etch process.

In one or more embodiments, the method 300 further includes a step 322of removing the TiN using a wet chemistry.

In one or more embodiments, the method 300 further includes a step 324of depositing a subsequent oxide layer over the metal layer in the viaholes.

Accordingly, it will be apparent that the method 300 provides asemiconductor wafer 400 that includes an underlayer 408; metal deposits406 in the underlayer; a sacrificial hardmask layer 404 that covers theunderlayer and the metal deposits; a titanium nitride layer 402 thatdirectly covers the sacrificial hardmask layer; an oxide layer 402 thatdirectly covers the titanium nitride layer; and a partial-depth via hole418 that is etched through the oxide layer to contact the titaniumnitride layer that directly underlays the oxide layer, wherein thepartial-depth via hole is aligned to one of the metal deposits in theunderlayer.

In one or more embodiments, the semiconductor wafer 400 also includes acompleted via hole 420 that is etched from the depth via hole throughthe titanium nitride layer to contact the metal deposit in theunderlayer.

In one or more embodiments, the semiconductor wafer 400 also includes ametal via 423 that is deposited into the completed via hole and contactsthe metal deposit in the underlayer. In one or more embodiments, themetal via has a substantially constant critical dimension.

One or more embodiments of the invention, or elements thereof, can beimplemented in the form of an apparatus including a memory and at leastone processor that is coupled to the memory and operative to performexemplary method steps, or in the form of a non-transitory computerreadable medium embodying computer executable instructions which whenexecuted by a computer cause the computer to perform exemplary methodsteps. FIG. 5 depicts a computer system that may be useful inimplementing one or more aspects and/or elements of the invention; forexample, by controlling semiconductor process equipment to implementaspects of the invention by providing instructions over network adapter20, discussed below.

In system 10 there is a computer server 12, which is operational withnumerous other general purpose or special purpose computing systemenvironments or configurations. Examples of well-known computingsystems, environments, and/or configurations that may be suitable foruse with computer server 12 include, but are not limited to, personalcomputer systems, server computer systems, thin clients, thick clients,handheld or laptop devices, multiprocessor systems, microprocessor-basedsystems, set top boxes, programmable consumer electronics, network PCs,minicomputer systems, mainframe computer systems, and distributed cloudcomputing environments that include any of the above systems or devices,and the like.

Computer server 12 may be described in the general context of computersystem executable instructions, such as program modules, being executedby a computer system. Generally, program modules may include routines,programs, objects, components, logic, data structures, and so on thatperform particular tasks or implement particular abstract data types.Computer server 12 may be practiced in distributed cloud computingenvironments where tasks are performed by remote processing devices thatare linked through a communications network. In a distributed cloudcomputing environment, program modules may be located in both local andremote computer system storage media including memory storage devices.

As shown in FIG. 5, computer server 12 in system 10 is shown in the formof a general-purpose computing device. The components of computer server12 may include, but are not limited to, one or more processors orprocessing units 16, a system memory 28, and a bus 18 that couplesvarious system components including system memory 28 to processor 16.

Bus 18 represents one or more of any of several types of bus structures,including a memory bus or memory controller, a peripheral bus, anaccelerated graphics port, and a processor or local bus using any of avariety of bus architectures. By way of example, and not limitation,such architectures include Industry Standard Architecture (ISA) bus,Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, VideoElectronics Standards Association (VESA) local bus, and PeripheralComponent Interconnect (PCI) bus.

Computer server 12 typically includes a variety of computer systemreadable media. Such media may be any available media that is accessibleby computer server 12, and it includes both volatile and non-volatilemedia, removable and non-removable media.

System memory 28 can include computer system readable media in the formof volatile memory, such as random access memory (RAM) 30 and/or cachememory 32. Computer server 12 may further include otherremovable/non-removable, volatile/non-volatile computer system storagemedia. By way of example only, storage system 34 can be provided forreading from and writing to a non-removable, non-volatile magnetic media(not shown and typically called a “hard drive”). Although not shown, amagnetic disk drive for reading from and writing to a removable,non-volatile magnetic disk (e.g., a “floppy disk”), and an optical diskdrive for reading from or writing to a removable, non-volatile opticaldisk such as a CD-ROM, DVD-ROM or other optical media can be provided.In such instances, each can be connected to bus 18 by one or more datamedia interfaces. As will be further depicted and described below,memory 28 may include at least one program product having a set (e.g.,at least one) of program modules that are configured to carry out thefunctions of embodiments of the invention.

Program/utility 40, having a set (at least one) of program modules 42,may be stored in memory 28 by way of example, and not limitation, aswell as an operating system, one or more application programs, otherprogram modules, and program data. Each of the operating system, one ormore application programs, other program modules, and program data orsome combination thereof, may include an implementation of a networkingenvironment. Program modules 42 generally carry out the functions and/ormethodologies of embodiments of the invention as described herein.

Computer server 12 may also communicate with one or more externaldevices 14 such as semiconductor fabrication process equipment inaccordance with aspects of the invention. Computer server 12 also maycommunicate with a display 24, etc.; one or more devices that enable auser to interact with computer server 12; and/or any devices (e.g.,network card, modem, etc.) that enable computer server 12 to communicatewith one or more other computing devices. Such communication can occurvia Input/Output (I/O) interfaces 22. Still yet, computer server 12 cancommunicate with one or more networks such as a local area network(LAN), a general wide area network (WAN), and/or a public network (e.g.,the Internet) via network adapter 20. As depicted, network adapter 20communicates with the other components of computer server 12 via bus 18.It should be understood that although not shown, other hardware and/orsoftware components could be used in conjunction with computer server12. Examples include, but are not limited to: microcode, device drivers,redundant processing units, and external disk drive arrays, RAIDsystems, tape drives, and data archival storage systems, etc.

Thus, one or more embodiments can make use of software running on ageneral purpose computer or workstation. With reference to FIG. 5, suchan implementation might employ, for example, a processor 16, a memory28, and an input/output interface 22 to a display 24 and externaldevice(s) 14 such as a keyboard, a pointing device, or the like. Theterm “processor” as used herein is intended to include any processingdevice, such as, for example, one that includes a CPU (centralprocessing unit) and/or other forms of processing circuitry. Further,the term “processor” may refer to more than one individual processor.The term “memory” is intended to include memory associated with aprocessor or CPU, such as, for example, RAM (random access memory) 30,ROM (read only memory), a fixed memory device (for example, hard drive34), a removable memory device (for example, diskette), a flash memoryand the like. In addition, the phrase “input/output interface” as usedherein, is intended to contemplate an interface to, for example, one ormore mechanisms for inputting data to the processing unit (for example,mouse), and one or more mechanisms for providing results associated withthe processing unit (for example, printer). The processor 16, memory 28,and input/output interface 22 can be interconnected, for example, viabus 18 as part of a data processing unit 12. Suitable interconnections,for example via bus 18, can also be provided to a network interface 20,such as a network card, which can be provided to interface with acomputer network, and to a media interface, such as a diskette or CD-ROMdrive, which can be provided to interface with suitable media.

Accordingly, computer software including instructions or code forperforming the methodologies of the invention, as described herein, maybe stored in one or more of the associated memory devices (for example,ROM, fixed or removable memory) and, when ready to be utilized, loadedin part or in whole (for example, into RAM) and implemented by a CPU.Such software could include, but is not limited to, firmware, residentsoftware, microcode, and the like.

A data processing system suitable for storing and/or executing programcode will include at least one processor 16 coupled directly orindirectly to memory elements 28 through a system bus 18. The memoryelements can include local memory employed during actual implementationof the program code, bulk storage, and cache memories 32 which providetemporary storage of at least some program code in order to reduce thenumber of times code must be retrieved from bulk storage duringimplementation.

Input/output or I/O devices (including but not limited to keyboards,displays, pointing devices, and the like) can be coupled to the systemeither directly or through intervening I/O controllers.

Network adapters 20 may also be coupled to the system to enable the dataprocessing system to become coupled to other data processing systems orremote printers or storage devices through intervening private or publicnetworks. Modems, cable modem and Ethernet cards are just a few of thecurrently available types of network adapters.

As used herein, including the claims, a “server” includes a physicaldata processing system (for example, system 12 as shown in FIG. 5)running a server program. It will be understood that such a physicalserver may or may not include a display and keyboard.

It should be noted that any of the methods described herein can includean additional step of providing a system comprising distinct softwaremodules embodied on a computer readable storage medium. The method stepscan then be carried out using the distinct software modules and/orsub-modules of the system, executing on one or more hardware processorssuch as 16. Further, a computer program product can include acomputer-readable storage medium with code adapted to be implemented tocarry out one or more method steps described herein, including theprovision of the system with the distinct software modules.

The following description is applicable to controlling semiconductorprocess equipment with computer instructions.

The present invention may be a system, a method, and/or a computerprogram product at any possible technical detail level of integration.The computer program product may include a computer readable storagemedium (or media) having computer readable program instructions thereonfor causing a processor to carry out aspects of the present invention.

The computer readable storage medium can be a tangible device that canretain and store instructions for use by an instruction executiondevice. The computer readable storage medium may be, for example, but isnot limited to, an electronic storage device, a magnetic storage device,an optical storage device, an electromagnetic storage device, asemiconductor storage device, or any suitable combination of theforegoing. A non-exhaustive list of more specific examples of thecomputer readable storage medium includes the following: a portablecomputer diskette, a hard disk, a random access memory (RAM), aread-only memory (ROM), an erasable programmable read-only memory (EPROMor Flash memory), a static random access memory (SRAM), a portablecompact disc read-only memory (CD-ROM), a digital versatile disk (DVD),a memory stick, a floppy disk, a mechanically encoded device such aspunch-cards or raised structures in a groove having instructionsrecorded thereon, and any suitable combination of the foregoing. Acomputer readable storage medium, as used herein, is not to be construedas being transitory signals per se, such as radio waves or other freelypropagating electromagnetic waves, electromagnetic waves propagatingthrough a waveguide or other transmission media (e.g., light pulsespassing through a fiber-optic cable), or electrical signals transmittedthrough a wire.

Computer readable program instructions described herein can bedownloaded to respective computing/processing devices from a computerreadable storage medium or to an external computer or external storagedevice via a network, for example, the Internet, a local area network, awide area network and/or a wireless network. The network may comprisecopper transmission cables, optical transmission fibers, wirelesstransmission, routers, firewalls, switches, gateway computers and/oredge servers. A network adapter card or network interface in eachcomputing/processing device receives computer readable programinstructions from the network and forwards the computer readable programinstructions for storage in a computer readable storage medium withinthe respective computing/processing device.

Computer readable program instructions for carrying out operations ofthe present invention may be assembler instructions,instruction-set-architecture (ISA) instructions, machine instructions,machine dependent instructions, microcode, firmware instructions,state-setting data, configuration data for integrated circuitry, oreither source code or object code written in any combination of one ormore programming languages, including an object oriented programminglanguage such as Smalltalk, C++, or the like, and procedural programminglanguages, such as the “C” programming language or similar programminglanguages. The computer readable program instructions may executeentirely on the user's computer, partly on the user's computer, as astand-alone software package, partly on the user's computer and partlyon a remote computer or entirely on the remote computer or server. Inthe latter scenario, the remote computer may be connected to the user'scomputer through any type of network, including a local area network(LAN) or a wide area network (WAN), or the connection may be made to anexternal computer (for example, through the Internet using an InternetService Provider). In some embodiments, electronic circuitry including,for example, programmable logic circuitry, field-programmable gatearrays (FPGA), or programmable logic arrays (PLA) may execute thecomputer readable program instructions by utilizing state information ofthe computer readable program instructions to personalize the electroniccircuitry, in order to perform aspects of the present invention.

Aspects of the present invention are described herein with reference toflowchart illustrations and/or block diagrams of methods, apparatus(systems), and computer program products according to embodiments of theinvention. It will be understood that each block of the flowchartillustrations and/or block diagrams, and combinations of blocks in theflowchart illustrations and/or block diagrams, can be implemented bycomputer readable program instructions.

These computer readable program instructions may be provided to aprocessor of a general purpose computer, special purpose computer, orother programmable data processing apparatus to produce a machine, suchthat the instructions, which execute via the processor of the computeror other programmable data processing apparatus, create means forimplementing the functions/acts specified in the flowchart and/or blockdiagram block or blocks. These computer readable program instructionsmay also be stored in a computer readable storage medium that can directa computer, a programmable data processing apparatus, and/or otherdevices to function in a particular manner, such that the computerreadable storage medium having instructions stored therein comprises anarticle of manufacture including instructions which implement aspects ofthe function/act specified in the flowchart and/or block diagram blockor blocks.

The computer readable program instructions may also be loaded onto acomputer, other programmable data processing apparatus, or other deviceto cause a series of operational steps to be performed on the computer,other programmable apparatus or other device to produce a computerimplemented process, such that the instructions which execute on thecomputer, other programmable apparatus, or other device implement thefunctions/acts specified in the flowchart and/or block diagram block orblocks.

The flowchart and block diagrams in the Figures illustrate thearchitecture, functionality, and operation of possible implementationsof systems, methods, and computer program products according to variousembodiments of the present invention. In this regard, each block in theflowchart or block diagrams may represent a module, segment, or portionof instructions, which comprises one or more executable instructions forimplementing the specified logical function(s). In some alternativeimplementations, the functions noted in the blocks may occur out of theorder noted in the Figures. For example, two blocks shown in successionmay, in fact, be executed substantially concurrently, or the blocks maysometimes be executed in the reverse order, depending upon thefunctionality involved. It will also be noted that each block of theblock diagrams and/or flowchart illustration, and combinations of blocksin the block diagrams and/or flowchart illustration, can be implementedby special purpose hardware-based systems that perform the specifiedfunctions or acts or carry out combinations of special purpose hardwareand computer instructions.

The descriptions of the various embodiments of the present inventionhave been presented for purposes of illustration, but are not intendedto be exhaustive or limited to the embodiments disclosed. Manymodifications and variations will be apparent to those of ordinary skillin the art without departing from the scope and spirit of the describedembodiments. The terminology used herein was chosen to best explain theprinciples of the embodiments, the practical application or technicalimprovement over technologies found in the marketplace, or to enableothers of ordinary skill in the art to understand the embodimentsdisclosed herein.

1. A semiconductor wafer comprising: an underlayer; metal deposits inthe underlayer; a sacrificial hardmask layer covering the underlayer andthe metal deposits; a titanium nitride layer directly covering thesacrificial hardmask layer; an oxide layer directly covering thetitanium nitride layer; and a partial-depth via hole that is etchedthrough the oxide layer to contact the titanium nitride layer thatdirectly underlays the oxide layer, wherein the partial-depth via holeis aligned to one of the metal deposits in the underlayer.
 2. The waferof claim 1 further comprising: a completed via hole that is etched fromthe partial-depth via hole through the titanium nitride layer to contactthe metal deposit in the underlayer.
 3. The wafer of claim 2 furthercomprising: a metal via deposited into the completed via hole andcontacting the metal deposit in the underlayer.
 4. The wafer of claim 3wherein the metal via has a substantially constant critical dimension.5. The wafer of claim 3 further comprising a second completed via holewith a via bar deposited into the second completed via hole andcontacting a plurality of metal deposits in the underlayer.
 6. The waferof claim 3 further comprising a subsequent oxide layer deposited overthe metal via.
 7. The wafer of claim 6 further comprising a trench levelstack deposited over the subsequent oxide layer.
 8. The wafer of claim 7further comprising a trench formed in the trench level stack and thesubsequent oxide layer to expose the metal via.
 9. The wafer of claim 1wherein the partial-depth via hole extends through an organicplanarization layer.
 10. The wafer of claim 9 wherein the partial-depthvia hole extends through a SiARC layer.
 11. An apparatus comprising:semiconductor fabrication process equipment; and a computer serveradapted to control the semiconductor fabrication process equipment toimplement a method that comprises: depositing an Nblock layer onto asemiconductor substrate that includes metal deposits; depositing atitanium nitride (TiN) layer directly onto the Nblock layer; depositingan oxide layer directly onto the TiN layer; and forming a partial-depthvia hole through the oxide layer to contact the TiN layer, wherein thepartial-depth via hole is aligned to one of the metal deposits in thesubstrate.
 12. The apparatus of claim 11 wherein the method furthercomprises: forming a completed via hole by etching the TiN layer throughthe partial-depth via hole; and forming a metal via by depositing ametal layer into the completed via hole and onto remnants of the oxidelayer.
 13. The apparatus of claim 12 wherein the method furthercomprises: after depositing the oxide layer, depositing an organicplanarization layer (OPL) directly onto the oxide layer and depositing asilicon anti-reflective coating (SiARC) directly onto the OPL; removingat least a portion of the OPL and the SiARC by etch after lithography;and forming the partial-depth via hole by etching the oxide layerthrough the removed portion of the OPL and the SiARC.
 14. The apparatusof claim 13 wherein the partial-depth via hole is formed while removingthe silicon anti-reflective coating (SiARC).
 15. The apparatus of claim14 wherein the method further comprises: after forming the partial-depthvia hole, stripping the OPL.
 16. The apparatus of claim 15 whereinetching the oxide layer uses a CFx chemistry for dry process.
 17. Theapparatus of claim 12 wherein etching the TiN layer uses a dry processchemistry that is selective to the oxide layer.
 18. The apparatus ofclaim 12 wherein etching the TiN layer uses a Cl₂ dry process.
 19. Theapparatus of claim 12 wherein the method further comprises: removing theTiN using a wet chemistry.
 20. The apparatus of claim 12 wherein themethod further comprises: reducing the metal layer by chemicalmechanical polishing.